Modelling resistance welding of thermoplastic composites with a nanocomposite heating element

Abstract

Electrically conductive nanocomposite heating elements are being developed as a complement to traditional carbon fibre or stainless steel heating elements in resistance welding of thermoplastic composites. Here we present the development of a finite element model of the resistance welding process with these new heating elements, from which we establish a process window for high quality welded joints. The finite element model results were validated experimentally and a lap shear strength improvement of 28% is reported relative to previously published results. Fractography analysis of the broken joints revealed a thin-layer cohesive failure mode due to the brittleness of the nanocomposite heating elements.